Multi-Layer Nonwoven Filtration Media for Meltblown Capacity

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Solution Overview

Problem

Existing facemasks with three-layer constructions face challenges in achieving Level 1 or Type 1 filtration efficiency while maintaining breathability and pressure drop, with the meltblown layer being a production bottleneck and limiting capacity during pandemics.

Innovation Solution

A filtration media comprising multiple nonwoven fabrics with reduced meltblown content, utilizing a SSMMS construct and a face-to-face configuration, allowing for improved filtration efficiency and reduced pressure drop, while optimizing the use of meltblown material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a three-layer construction with traditional meltblown layer is used, then filtration efficiency is achieved, but production capacity is limited due to meltblown bottleneck

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidproduction capacity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent divides the meltblown layer into multiple separate nonwoven fabric layers, each containing a portion of the total meltblown content. This segmentation allows each layer to be produced independently at lower speeds, eliminating the bottleneck of producing a single large meltblown layer and thereby increasing overall production capacity while maintaining filtration efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite nonwoven fabric constructions where multiple layers of different materials (spunbond, meltblown, hydroentangled) are combined. This allows the system to achieve the required filtration efficiency through the composite structure while using reduced total meltblown content, thus resolving the production capacity limitation.

Inventive Principle:

Principle #40Composite materials

2Productivity

If meltblown content is reduced, then production capacity increases, but filtration efficiency may deteriorate

Engineering Contradiction:

Improveproduction capacityVSAvoidfiltration efficiency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

By segmenting the meltblown content across multiple nonwoven fabric layers, the patent maintains sufficient filtration efficiency through distributed filtration surfaces. Each layer contributes to the overall filtration function, ensuring that reduced total meltblown content does not compromise filtration performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different material compositions and structures to different layers of the filtration media. By optimizing the local properties of each nonwoven fabric layer (e.g., using hydroentangled layers for structural support and spunbond layers for breathability), the system achieves required filtration efficiency with reduced overall meltblown content.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If single fabric construct is used, then manufacturing is simplified, but breathability and pressure drop performance are insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidbreathability

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The patent segments the single fabric construct into multiple separate nonwoven fabric layers that are assembled together. This segmentation allows each layer to be optimized for specific functions (breathability, filtration, structural support), thereby improving overall breathability and pressure drop performance while maintaining manufacturing simplicity through modular assembly.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enables the production of more facemasks with reduced meltblown material, achieving desired filtration efficiency and breathability, suitable for Level 1 and Type 1 facemasks, with a lower pressure drop and efficient use of materials.

Implementation Method 1

filtration media including at least one nonwoven fabric layer (e.g., a plurality of individual nonwoven fabric layers), in which the at least one nonwoven fabric layer includes a relatively low basis weight of meltblown fibers

Methodology Applied

Scientific EffectPhysical barrier filtration: Filter (physical)

Implementation Method 2

an internal meltblown layer from about 20 to about 25 gsm

Methodology Applied

Scientific EffectElectrostatic attraction: Electrostatics

Implementation Method 3

maintaining their breathability levels or pressure drop values

Methodology Applied

Scientific EffectPorosity: Porosity

Data Source

PatentUS20250262582A1Filtration media

Publication Date: 2025.08.21 MAGNERA CORP

AI summary

A filtration media including at least a first nonwoven fabric having at least one meltblown layer in provided. The at least one meltblown layer includes a plurality of meltblown fibers having an average diameter from about 1 to about 5 microns. Methods of making a filtration media are also provided. Facemasks including such filtration media are also provided.